Sign up to receive free email alerts when patent applications with chosen keywords are publishedSIGN UP

Abstract:

The present invention encompasses edible carriers for foods that are soft
but still hold a preformed shape. Specifically encompassed are soft
shaped tortilla products that can be used to hold food fillings.
Exemplary shapes and sizes are provided for the products. Also
encompassed are methods of making, packaging, and using the products.

Claims:

1. (canceled)

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. (canceled)

7. (canceled)

8. (canceled)

9. (canceled)

10. (canceled)

11. (canceled)

12. (canceled)

13. (canceled)

14. (canceled)

15. (canceled)

16. (canceled)

17. (canceled)

18. (canceled)

19. (canceled)

20. (canceled)

21. (canceled)

22. (canceled)

23. (canceled)

24. (canceled)

25. (canceled)

26. (canceled)

23. (canceled)

24. (canceled)

28. (canceled)

29. (canceled)

30. (canceled)

31. A packaged food article, comprising:a hermetically sealed food package
having a headspace;at least one baked soft shaped tortilla piece having a
thickness ranging from about 1-5 mm disposed therein said soft shaped
tortilla pieces having a water activity of 0.88 or less; and,a headspace
gas.

32. The packaged food article of claim 31 wherein the food piece ranging
from about 40-60 g in weight.

33. The packaged food article of claim 32 wherein the food piece is
fabricated from a cooked farinaceous tortilla dough having a finished
moisture content of 25% or less.

36. The packaged food article of claim 35 wherein the sealed food package
is fabricated at least in part from a flexible packaging film.

37. The packaged food article of claim 36 wherein the food package has an
oxygen permeability of less than 2.5 ccO2/cm2/day and wherein
the headspace gas has an oxygen level of less than 4%.

38. The packaged food article of claim wherein the headspace gas includes
N2 and CO.sub.2.

39. The packaged food article of claim 38 comprising a plurality of soft
shaped tortilla pieces each of a nestable configuration arranged in
nested stacked relationship to form at least one stack.

40. The packaged food article of claim 33 wherein the stack is mounted
within a supplemental support carrier.

41. The packaged food article of claim 40 wherein the pieces are arranged
in at least two stacks.

42. The packaged food article of claim 31 having a shelf life of at least
six months at room temperature storage and wherein the piece has a water
activity ranging less than about 0.88.

43. The packaged food article of claim 42 wherein the headspace has an
oxygen level of less than 1%.

44. The packaged food article of claim 43 wherein the shaped tortillas are
in the form of a boat.

45. A meal kit for use in making a Mexican soft shaped tortilla,
comprising:an outer package;a first soft shaped tortilla base pieces
package food article disposed within the outer package including:a
hermetically sealed food package having a headspace;a quantity of baked
soft shaped tortilla pieces disposed therein said soft shaped tortilla
pieces fabricated from a farinaceous dough having a water activity of
0.88 or less; and,a headspace gas having an oxygen level of less than 4%;
and,a second packaged food article disposed within the outer package that
is either a pouch of dry seasoning mixture or a pouch of a wet sauce.

46. The meal kit of claim 45 wherein the seasoning mix includes seasoning
for flavoring meat.

47. The meal kit of claim 46 wherein the outer package is a carton wherein
the carton includes a front major panel and a rear major panel.

48. The meal kit of claim 47 additionally including an instructions legend
for preparing Mexican tortilla using the meal kit.

49. The meal kit of claim 48 wherein the instruction legend is on rear
major panel of the carton.

50. The meal kit of claim 49 wherein the second packaged food article is a
pouch of dry seasoning mixture for meat.

51. The packaged food article of claim 50 wherein the first food package
article has an oxygen permeability of less than 2.5 cc
O2/cm2/day and a headspace oxygen level of less than 2%.

52. A method of preparing a baked soft shaped tortilla piece packaged food
article, comprising the steps of:A. providing a quantities of a
chemically leavened gluten plastic dough;B. forming the quantities into
shaped heat set three dimensional pieces having a thickness of about 1-5
mm;C. baking the shaped heat set pieces to form finished soft shaped
tortilla piece having a moisture content of about 25% or less and having
a water activity value of about 0.88 or less; and,D. packaging a number
of finished soft shaped tortilla piece within a modified atmosphere
package to form soft shaped tortilla piece packaged food article having a
shelf life of at least six months at room temperature storage.

53. The method of claim 52 wherein the dough is a worked farinaceous
dough, comprising:about 55 to 80% (dry weight basis) of the dough as
flour and wherein at least a majority of the flour is wheat flour;about
1%-10% sugar;about 4%-15% humectant;about 1%-3% of a chemical leavening
system including at least one baking acid and soda;about 10%15% fat;about
1%-5% salt; and,about 30%-35% moisture.

53. The method of claim 52 wherein the dough is a rested farinaceous
dough.

54. The method of claim 53 wherein each quantity of dough in stepA ranges
from about 40-60 g and wherein the dough has a Brabender value ranging
from about 500 to 1000 BU.

55. The method of claim 54 wherein the forming step is practiced in a mold
heated to about 190.degree. C. to 205.degree. C.

56. The method of claim 55 wherein forming step is practiced to form a
par-baked intermediate food item and the baking step is practiced in a
belt oven.

Description:

FIELD OF THE INVENTION

[0001]The present invention relates to edible holders for foods that are
soft but still retain a preformed shape. More specifically, the present
invention relates to soft shaped tortilla products, that can be used to
hold various edible fillings, and to kits comprising a packaged
multiplicity of soft shaped tortilla base pieces. Also related are
methods of making, packaging, and using said products.

BACKGROUND OF THE INVENTION

[0002]Consumers are searching for healthy and yet convenient food options,
avoiding foods laden with excess fats. There is a movement away from
unhealthy choices such as crispy deep fried foods. As healthier options,
low fat options such as Lebanese breads and pita pockets are used as a
carrier for toppings or sandwich ingredients. Yet, they can be too thick,
and are likely to break while consumers attempt to fold them into shapes
that are convenient to hold and carry. They also show a limited shelf
life, and can dry out quickly due to their formulation. Mountain breads
can (flat square breads sold in Australia) can also be used, but are more
suitable for lunch more than dinner. Also, they are too thin to be used
with sauces, and show a limited shelf life. Naans and chapatis are exotic
choices more suitable for a main meal than as a lunchtime wrap. In
addition, they tend to be inflexible, too small, and high in fat.

[0003]By comparison, tortillas are shelf stable, highly soft and flexible,
and can fold and bend without breaking. The term "tortilla" is used
herein to refer to a Mexican style tortilla, i.e., a generally flat
unleavened cooked flexible pan baked dough product generally circular in
shape such as from a corn masa dough ("tortilla de maiz") or from a wheat
dough ("tortilla de harina"). The two versions of the Mexican tortilla
have different textures owing to the grains from which they originate.
The maize version is somewhat thicker and heartier in texture, while the
wheat version is less easily broken, due to its elevated gluten content,
and therefore often larger in circumference. Tortillas are suitable for
lunch and dinner, with a unique taste and texture compared to other forms
of bread. However despite these advantages, consumers have difficulties
"managing" a tortilla. The amount of filling is often miscalculated while
folding, sealing and holding can be a challenge. As such, tortillas can
be inconvenient, messy, and frustrating, especially for children and
their parents. While the art includes moulding precooked tortillas by
heating in a microwave, this produces an unsatisfactory product that
fails to hold its shape and lacks a true baked texture. Microwaving a
precooked tortilla is inadequate for setting the protein structure in the
tortilla to form a shape and relies upon drying to form shaped article.
With this method, one is forced to overcook the tortilla to produce a
hard (e.g., cardboard-like) and excessively tough result.

[0004]Thus, there is a need in the art for a soft shaped tortilla product
that is easy to use, less messy, delicious to eat and healthier than
other options. Also, there is a need in the art for methods for
manufacturing and using such a product.

BRIEF SUMMARY OF THE INVENTION

[0005]The invention generally encompasses a low fat shelf stable soft
tortilla fabricated from a Mexican tortilla such as a chemically leavened
cooked cereal dough that is formed into a variety of thin walled rigid
three dimensional shapes that are rigid yet soft and flexible and which
are useful for edible containers of loose particulate food stuffing, and
wherein the shape is other than (a) flat, (b) flat or in the shape of a
cup or bowl, (c) flat or boat/canoe shaped or (d) flat, in the shape of a
cup or bowl or boat/canoe shaped.

[0006]In a particular aspect, the invention encompasses a soft shaped
tortilla that is formed into shape for holding fillings, wherein the
shape is other than (a) flat or (b) flat or boat/canoe shaped, flat, and
wherein the final moisture content of the tortilla is between about 23%
to about 25%.

[0007]In one aspect, the tortilla is formed to hold the shape of a cup or
bowl.

[0008]In other aspects, the tortilla is formed into the shape of a U- or
square bottomed shaped taco shell, boat/canoe, pita, flower, pie, tube,
envelope, pod, bun, or cone. (square bottomed)

[0009]In still other aspects, the tortilla comprises a flat bottom and
sealed sides.

[0010]In yet other aspects, the tortilla comprises an edible string.

[0011]The invention also generally encompasses a method of making a soft
tortilla which is formed into a shape, wherein the shape is other than
flat.

[0012]In a first specific aspect, the invention encompasses a method of
producing a soft shaped tortilla, comprising: pressing raw tortilla dough
into a mould, and heating the dough in the mould without deep fat frying
until the dough is at least substantially cooked and formed into the
shape of the mould.

[0013]In a second specific aspect, the invention encompasses a method of
producing a soft shaped tortilla, comprising: pressing raw tortilla dough
into a mould, heating the dough without deep fat frying long enough to
form the dough into a rigid article conforming to the shape of the mould,
removing the shaped dough from the mould, and heating the shaped dough
(e.g., in an oven or other heating device) until fully cooked.

[0014]In a third specific aspect, the invention encompasses a method of
producing a soft shaped tortilla, comprising: heating flattened tortilla
dough until fully cooked, pressing the preheated/precooked tortilla into
a mould while still warm and pliable, and cooling the tortilla to set the
tortilla into the shape of the mould.

[0015]In a fourth specific aspect, the invention encompasses a method of
producing a soft shaped tortilla, comprising: rolling raw tortilla dough
into a sheet, pressing the sheet into a mould, heating the dough long
enough to form into the shape of the mould, removing the shaped dough
from the mould, and heating the shaped dough until fully cooked.

[0016]In a fifth specific aspect, the invention encompasses a method of
producing a soft shaped tortilla, comprising: injecting raw tortilla
dough or batter into a mould, and heating the dough or batter in the
mould until it is fully cooked and formed into the shape of the mould.

[0017]In a sixth specific aspect, the invention encompasses a method of
producing a soft shaped tortilla, comprising: injecting raw tortilla
dough or batter into a mould, heating the dough long enough to form into
the shape of the mould, removing the shaped dough from the mould, and
heating the shaped dough (e.g., in an oven or other heating device]
device) until fully cooked.

[0018]The method can further comprise causing the dough to rise in an
irregular manner so as to cause brown points.

[0019]The method can still further comprise using two cooking moulds,
wherein the first mould comprises a cavity in the shape of the tortilla
product; and the second mould comprises a protrusion shaped to fit into
the cavity of the first mould. The moulds can be preheated prior to use.

A hermetically sealed food package; [0021]A quantity of baked soft
shaped tortilla pieces disposed therein said soft shaped tortilla pieces
having a water activity of 0.88 or less; and, [0022]A headspace gas
having an oxygen level of less than 5%

[0023]In another article aspect of the one and same invention, meal kits
are provided. The meal kits include meal kit for use in making a Mexican
soft shaped tortilla, comprising: [0024]An outer package; [0025]A first
soft shaped tortilla base pieces package food article disposed within the
outer package including: [0026]A hermetically sealed food package;
[0027]A quantity of baked soft shaped tortilla pieces disposed therein
said soft shaped tortilla pieces fabricated from a farinaceous dough
having a water activity of 0.88 or less; and, [0028]A headspace gas
having an oxygen level of less than 5%; and, [0029]A second packaged food
article disposed within the outer package that is either a pouch of dry
seasoning mixture or a pouch of a wet sauce. [0030]In another article
aspect of the one and same invention, methods are provided of preparing a
soft shaped tortilla base piece packaged food article, comprising the
steps of: [0031]providing a quantities of a chemically leavened gluten
plastic or viscoelastic dough; [0032]forming the quantities into shaped
heat set pieces; [0033]balking; the shaped heat set pieces to form
finished soft shaped tortilla base pieces; and, [0034]packaging a number
of finished soft shaped tortilla base pieces within a modified atmosphere
package to form a soft shaped tortilla base piece packaged food article.

[0035]While multiple aspects are disclosed, still other aspects of the
present invention will become apparent to those skilled in the art from
the following detailed description, which shows and describes
illustrative embodiments of the invention.

[0036]As will be realized, the invention is capable of modifications in
various obvious aspects, all without departing from the spirit and scope
of the present invention. Accordingly, the drawings and detailed
description are to be regarded as illustrative in nature and not
restrictive.

[0047]FIG. 10 is an exploded perspective view of a meal kit of the present
invention including a carton housing a nested array of shaped tortillas
food packaged article of the present invention as well as a dry pouch and
a wet pouch of secondary food ingredients.

DETAILED DESCRIPTION OF THE INVENTION

[0048]The present invention relates to improved shelf stable consumer
packaged food articles including components fabricated from a Mexican
tortilla like chemically leavened cooked farinaceous dough in a variety
of thin walled three dimensional set or rigid shaped forms yet soft and
flexible that are useful for edible containers of loose particulate food
stuffing and to methods for their preparation.

[0049]Throughout the specification and claims, percentages are by weight
and temperatures in degrees Centigrade unless otherwise indicated.

[0050]The present consumer packaged food articles comprise at least one
soft shaped tortilla piece as its principal edible component. As used
herein, a "soft shaped tortilla" or, equivalently, a "shaped soft
tortilla" means a fully cooked but non-fried tortilla farinaceous dough
product that is formed into a thin walled three dimensional shape of
sufficient rigidity to holds its shape at room temperature. Thus,
"tortilla" means a fully cooked product. By comparison, "tortilla dough"
means uncooked or partly cooked product. "Fully cooked" is understood to
be a product that reaches about 85° C. (+/-2 degrees), and is
evidenced by substantially all of the starch being gelatinized.

[0051]Broadly, in one article aspect, the present invention comprises a
soft shaped tortilla in a variety of specific three dimensional shapes or
configurations. These shaped food articles are useful as the principal
edible components of consumer packaged food product articles.
Traditionally, in northern Mexico, tortillas are cooked unleavened
flexible flat breads typically in thin or flat, circular or elliptical
shape useful as an edible bread wrap for small quantities of other foods
such as meat pieces, rice, and/or vegetables mixture. Thus, the present
food articles are to be distinguished from egg or egg omelet based dishes
often referred to as "tortillas" (Tortilla de patatas) in other Spanish
speaking locations.

[0052]In one aspect, the present disclosure encompasses a soft shaped
tortilla product with the shape being defined as being other than flat.
(a) flat, (b) flat or in the shape of a cup or bowl, (c) flat or
boat/canoe shaped, or (d) flat in the shape of a cup or bowl, or
boat/canoe shaped.

[0053]In another aspect, the disclosure encompasses a soft shaped tortilla
that is formed into three dimensional shape suitable for holding
fillings, wherein the shape is other than (a) flat or (b) flat or
boat/canoe shaped.

[0054]The final moisture content of the soft shaped tortilla is less than
about 28% (˜≦28%), preferably ˜≦25%. In
preferred form, the soft shaped tortillas are shelf stable and exhibit a
water activity value ("Aw") of ˜≦0.88. In less
preferred variations, the soft shaped tortilla pieces are suitable only
for refrigerated distribution and sale and exhibit an Aw of
˜≦0.92.

[0055]The particular selection of ingredients and concentration are
selected to provide finished soft shaped tortilla products having a water
activity ("Aw") of 0.88 or less and for best results less than 0.85 to
about 0.7. Selection of such water activity value is important in
achieving a balance between microbial shelf stability and dough handling
characteristics. Water activity can also be reduced by using polyols such
as glycerol and sorbitol. Good results are obtained when the moisture
content of the finished product ranges from about 10% to about 25%,
preferably about 15% to 20%.

[0056]The invention disclosure further encompasses a method of making a
soft shaped tortilla product.

[0057]In one particular aspect, the invention disclosure encompasses a
tortilla (e.g., round, flour tortilla) that is hot formed to hold the
shape of a cup or bowl, e.g., a salad bowl. In other aspects, the
tortilla can be formed to rigidly hold the shape of taco (i.e., U-shaped
taco shell) or the shape of a boat/canoe. In still other aspects, the
tortilla can be formed to hold the shape of a pita, flower bud, pie,
tube, envelope, pod, bun, or cone. The formed shape can have a flat
bottom and sealed sides.

[0058]In accordance with the invention, the soft shaped tortilla articles
can be provided in a variety of sizes from jumbo burrito size to mini
chalupa size. A "chalupa" (Spanish for "boat" or "launch") is a tortilla
dough formed into a shape reminiscent of a small boat. As starting
material, it is possible to use round precooked tortillas or rounded
flatted tortilla dough that is about 76 mm, about 102 mm, about 127 mm,
about 152 mm, about 178 mm, about 191 mm, about 203 mm, about 229 mm,
about 254 mm, or up to about 305 mm, or more, in diameter. For example, a
190 mm diameter precooked tortilla or flattened tortilla dough can be
used to give a cup dimension of about 89 mm diameter and about 51 mm
height. It is also possible to use precooked tortillas or flattened,
pre-cut pieces of dough that are cut to easily fit into a mould for
shaping. The starting material can be any shape suitable for the final
mould, for example, round, oval, crescent, square, rectangular,
trapezoid, triangular, etc.

[0059]In one aspect, the overall size of the soft shaped tortilla is such
it is portable to hold, and that the consumer can take mouth sized bites.
In this aspect the width of the soft shaped tortilla is no wider than the
distance an average adult mouth may comfortably open when consuming a
sandwich. In another aspect, the width of the soft shaped tortilla is no
wider than the distance an average child mouth may comfortably open when
consuming a sandwich. In one particular aspect, the overall width after
forming is about 25 mm or less, or about 12 to about 25 mm, for example,
for children. In one other aspect, the width is about 37 mm or less, or
about 12 to 37 mm, for example, for adults.

[0060]In another aspect, the height of the soft shaped tortilla is limited
to the distance an average adult mouth can comfortably open when
consuming a sandwich. In another embodiment the height of the soft shaped
tortilla is limited to the distance an average child's mouth can
comfortably open when consuming a sandwich. In a specific aspect, the
height of the soft shaped tortilla is about 25 mm or less, or about 12 to
about 25 mm, for example, for children. In another aspect, the height is
about 37 mm or less, or about 12 to about 37 mm, for example, for adults.

[0061]As a larger size, the soft shaped tortilla will have a width of at
least about 25 mm. In another aspect, the width is limited to the bite
width of an average adult mouth. In yet another aspect, the width is
limited to the bite width of an average child's mouth. In a particular
aspect the width of the soft shaped tortilla is about 25 to about 51 mm,
for example, for children. In one other aspect, the width is about 37 to
about 75 mm, for example, for adults.

[0062]Depending on the final form of the tortilla, the overall diameter of
the soft shaped tortilla (e.g., for the leading part which is directed
into the mouth) can be any size from about 10 mm, about 12 mm, about 15
mm, about 20 mm, about 25 mm, about 30 mm, about 35 mm, about 37 mm, and
about 40 mm, or for example, from about 12-37 mm.

[0063]Regardless of specific shape, a feature of the present soft shaped
tortilla articles is a thin walled construction characteristic of a
tortilla. Good results are obtained in terms of sufficient rigidity as to
maintain the desired structure while nonetheless providing a soft eating
quality characteristic of wheat tortillas, is obtained when the present
articles are fabricated with wall thicknesses ranges from about 1-5 mm,
preferably about 24 mm. For example, in one specific embodiment, the
thickness of the soft shaped tortilla can be about 1.3 mm, about 2.3 mm,
about 3.3 mm, or about 3.8 mm.

[0064]Good results are obtained when the present shaped tortilla articles
are fabricated having a length ranging from about 50 mm to about 250 mm.
In certain embodiments, the articles range from about 70 mm to about 200
mm in length. In certain specific embodiments, the articles have a length
of, about 150 mm, while in certain other specific embodiments having a
length of about 170 mm, about 190 mm, about 200 mm, about 250 mm, or more
or in a range of from about 50-mm to about 200 mm.

[0065]In another variation, the shaped tortilla of the present invention
can be made using a standard tortilla having a thickness less than 1.5 mm
or a thickness greater than or equal to 1.5 mm. As mentioned above, range
on thickness could be 0.5-5 mm Consequently, in one aspect, the shaped
tortilla can be made from a standard tortilla having a thickness of about
1.5 to about 3.0 mm, or greater. In one aspect, then, the shaped tortilla
can be made from a standard tortilla having a thickness of about 1 to
about 2.0 mm, or greater.

[0066]In one particular aspect, the cavity of the shaped tortilla is
larger than the cavity of the conventional tortilla. Consequently, the
shaped tortilla can hold a greater amount of filling than the
conventional tortilla. In this way, the shaped tortilla can be filled
with greater amounts of meat and still have room for adequate amounts of
all other available fillings. The cavity of the shaped tortilla can also
provide consistent wrapping to filling ratio throughout the product. As
such, the tortilla fillings can be enjoyed down to the last bite, as
opposed to the last bite being a mouthful of dough. This provides for
greater eating satisfaction and, as a result, will be preferred by a
consumer. In addition, the larger cavity allows a utensil (e.g., spoon)
to be used to access the cavity when used to load the filling.

[0067]Notably, each of the disclosed shapes provides benefits to the
consumer. The boat/canoe shape (e.g., FIG. 1) is easy to fill, holds a
large amount of fillings, and allows layering of fillings. The pita shape
(e.g., FIG. 2) is easy to hold and use, fitting naturally into the hands.
It is a familiar shape and provides consumers with an indication when
maximum filling is reached. The flower bud shape (e.g., FIG. 3) is easy
to fill and provides the option to fold or leave open. It allows one
handed eating, which is easy for kids and suitable for consumers on the
go. The round bottom allows filling down to the last bite. The pie shape
(e.g., FIG. 4) is unique, impressive, and ideal for entertaining. It has
a large opening which is easy to fill.

[0068]As another option, the tube shape (e.g., FIG. 5) is easy to hold
together, making it neater to eat. It has a wide bottom which allows for
large amounts of filling. The envelope shape (e.g., FIG. 6) provides a
flap to fold over. This looks tidy and prevents ingredients from falling
out. It also sits flat on the plate making it easier to fill. The pod
shape (e.g., FIG. 8) is unique, fun, and adaptable. The pods can be used
separately, for example, for dips, or can be used as a set, for example,
to fill with different ingredients. The boat shape (e.g., FIG. 7) is kid
friendly and very adaptable, as it can also work as a dessert option. For
example, it can be presented as a sweetened tortilla filled with fruit
chocolate, cinnamon, etc. In another aspect, the shaped tortilla can be
formed into that of a salad bowl (e.g., FIG. 8). Although not as portable
as other shapes, it does offer an alternative for use in restaurant or
food service venues, as a non-fried taco salad option.

[0069]In a preferred aspect, the precooked tortilla or tortilla dough is
formed into a rounded shape, e.g., a cup or a bowl, or optionally, a taco
shape (i.e., U-shaped taco shell), boat/canoe shape, pita shape, flower
shape, pie shape, tube shape, bun shape, or cone shape. Yet, it is
understood that the disclosed shapes are exemplary, and that any shape
can be utilized in accordance with the invention. In addition, each of
the described shapes can be modified as needed, for example, for the
boat/canoe shape, one or more of the ends can be folded high, and for the
pita shape, the product can include a flap that folds over.

[0070]It will be further understood that the shaped tortillas can be
prepared from a variety of cereal flours, for example, with white flour,
corn flour, masa flour, whole wheat flour, multigrain flour, whole grain
flour, rice flour, gluten-free flour, or any combination thereof. The
dough can additionally include added herbs, seasonings and flavour
ingredients to provide general flavours such as Mexican, Italian,
Mediterranean, Asian, Caribbean, and Indian; and specific flavours such
as jalapeno, chipotle, cheese, black bean, red chilli, pesto, herb,
garlic, rosemary, vegetable, spinach, sundried tomato, basil, cilantro,
or any combination thereof; and dessert flavours such as chocolate,
blueberry, pineapple, banana, honey, and apple cinnamon, or any
combination thereof.

[0071]In one aspect, the shaped tortillas (e.g., bun shaped products) are
used in conjunction with edible string. This can be used to provide fun
for kids and increased portability for work lunches. In various aspects,
one or more different flavours of string can be used with one tortilla.

[0072]In accordance with the invention, the shaped tortillas can be used
as `blank canvas` allowing consumers to create own taste preferences and
also experiment as tortilla taste compliments all kinds of flavours and
ingredients. The shaped tortillas allow a large number of options for
fillings and folding. The texture and thickness of the shaped tortillas
is ideal for a variety of meal choices. It is flexible enough to hold
fillings and avoid breakage, and moist enough to please the palate.

[0073]In particular, the shaped tortillas can be used as a breakfast
alternative (e.g., with cooked eggs, omelettes, ham, bacon, or
VEGEMITE® brand food paste (which is a dark brown food paste made from
yeast extract, used mainly as a spread on sandwiches, toast and cracker
biscuits, as well as a filling of pastries. VEGEMITE food paste is made
from leftover brewers' yeast extract, a by-product of beer manufacturing,
and various vegetable and spice additives), for lunch (cold fillings such
as salad, ham, lunch meats, etc.), and for dinner (hot fillings such as
meats, vegetables, etc.). It will be understood that Mexican fillings
(e.g., taco, burrito fillings) are specifically envisioned, including
lettuce, beans, peppers, cheese, cooked meat or poultry, sauce, sour
cream, guacamole, etc.

[0074]The present invention features a number of advantages. It allows
consumers to place many types of fillings (e.g., salad greens, taco
fillings, etc.) inside, but is lighter and healthier than a fried shell
or a bread bowl. It gives the advantage of being able to hold the
fillings in the tortilla while reducing the problem of filling falling
out the sides of a typical taco shell or tortilla. The ends of the formed
tortilla can be sealed, so there is minimized leaking out of the end of
the tortilla. The sides of the tortilla can rise from the base slightly
so that fillings are less likely to leak out during filling. Optional
side extensions can make the tortilla enclosed.

[0075]In this way, the invention provides the convenience of a pre-formed
shell, in pliable, healthier, low mess presentation. The invention gives
consumers the option of a soft, neater to eat tortilla. The shaped
tortillas remain tender and malleable to give the true tortilla eating
experience with minimal cracking. The shaped tortillas of the invention
are clearly distinguished from shells which are deep fried and crispy.
The invention is unique in that it provides for tortillas to retain a
predetermined shape without the need for frying, while maintaining a soft
texture. Also, the present products are to be distinguished from smaller
bite-sized tortilla chips which are crisp and frangible whether made by
deep fat frying or baking or other bite sized carriers, or holders.

[0076]As further advantages, the shaped tortillas can be made on a
sheeting line with high throughput. The shapes can be stackable for
compact packaging. The tortilla products can be provided in a shelf
stable format with re-sealable packaging. The soft format of the formed
tortillas avoids the breakage and wastage associated with hard shelled
holders. The portability of the shaped tortillas gives consumers the
freedom to eat at home, at work or on the go. It provides consumers with
convenient eating solutions, including spontaneous and last minute meal
options.

[0077]The invention also encompasses a method of making a soft tortilla
which is formed into a shape. The method can comprise putting raw
tortilla dough in a mould and cooking it to completion to set the shape.
Alternatively, the method can comprise heating raw tortilla dough in a
mould to set the tortilla shape without fully cooking it. The shaped
dough is then heated in a further step to fully cook it, so as to cause
the structure to become firm, and to lower the moisture level.

[0078]As another alternative, the method can comprise preheating flattened
tortilla dough; further heating the flattened dough in a mould to set the
shape; and further heating the moulded dough to fully cook it and to
reduce the moisture content. In a further alternative, the method can
comprise heating a flat precooked and preheated tortilla; wrapping the
heated, flat precooked and preheated tortilla around a mould to form a
shape; and allowing the warm, shaped soft tortilla product to cool in a
manner that retains the shape and reduces the moisture content.

[0079]As a still further alternative, the method can comprise injecting
raw dough or batter into a mould and cooking it to completion to set the
shape. In an even further alternative, the method can comprise injecting
raw dough or batter into a mould and heating it to set the shape without
fully cooking it. The shaped dough is then heated in a further step to
fully cook it, so as to cause the structure to become firm, and to lower
the moisture level.

[0080]The method can further comprise causing the dough to create gas
bubbles in an irregular manner so as to cause browned areas or points.
The method can still further comprise using two heated cooking moulds,
wherein the first mould comprises a cavity in the shape of the tortilla
product; and the second mould comprises a protrusion shaped to fit into
the cavity of the first mould. These are commonly called male and female
moulds.

[0081]It should be noted that, while the present invention finds
particular suitability for use in connection with the provision of white
flour based recipes, the skilled artisan will appreciate that the present
invention finds usefulness in provision of recipes encompassing corn
flour, masa flour, rice flour, wheat flour, multigrain flour, whole grain
flour, or any combination thereof, including wheat/white blends,
multigrain/white blends, masa/white blends. The shaped tortillas can be
prepared as products that are reduced fat (,i.e., reduced or lower in fat
compared or relative to fried tortilla shells) having a fat content of
20% or less, or low fat, reduced or low carbohydrate, or reduced or low
sodium, or "lite", or any combination thereof. By "low fat" is meant
herein a product having a fat content of 10% or less. In certain
preferred embodiments, the present tortilla products have fat levels
ranging from about 5-9% fat.

[0082]For corn tortillas, masa dough can be formed. This can be done by
purchasing masa dough from a vendor, purchasing masa flour, and mixing it
with water, annatto (an optional yellow colouring), salt, and rework to
form the dough, or by purchasing raw corn and processing it to make the
masa dough. If raw corn is purchased, the raw corn is cooked with lime
and then steeped. The corn is then washed and ground into masa flour,
which is then mixed with other ingredients to form the dough.

[0083]The dough (i.e., any type or flavour) can be processed through a
sheeting machine to form flat raw tortilla dough. In one embodiment, the
flat raw highly developed tortilla dough is placed onto moulds prior to
heating. In another embodiment, the tortilla dough is pre-heated during
flattening, before placement. In an alternate embodiment, the tortilla
dough is cooked before placement onto the moulds. According to the
invention, the moulds can be solid, or vented and/or perforated, or
conventional forms having upper and lower plates.

[0084]The tortillas or tortilla dough (preheated or not) can then be
heated to adopt the form of the moulds. For this heating, the tortillas
or tortilla dough can optionally be baked, resulting in tortillas with
toast marks. This also reduces moisture content. After heating, the
moulded products exit as one or more shapes described herein. Since the
formed tortillas are still pliable for short periods while still hot
immediately after heating, care is taken to preserve the desired shape.
The shapes become more rigid as the tortillas cool.

[0085]The shaped products are heated to reduce the moisture content. For
this, any warm heat source can be used. Baking is preferred, including
baking by conventional ovens, convection ovens, rotary rack ovens, brick
ovens, infra-red ovens, tortilla ovens, and toaster ovens. Grilling can
also be used. In certain aspects, the invention specifically excludes the
use of microwave heating. Preferably, the shaped tortillas are heated to
retain softness while avoiding a tough, chewy, or soggy texture. In
various aspects, the moisture content of the final product can be in a
range from about 23% to about 28%, or specifically, about 24%, about 25%,
or about 26%. In particular aspects, the water activity of the final
product can be in a range of about 0.82 to about 0.92, or less than 0.88.

[0086]In the preferred embodiment, the shaped soft tortilla piece is
fabricated from a dough formulation from a chemically leavened wheat
based or farinaceous baked developed or gluten structured dough. Batters
and doughs as used herein are distinguishable compositions even though
each comprises some number of common ingredients. "Dough" as used herein
refers to an intermediate food product that has a gluten-based structure.
In dough, the gluten forms a continuous dough elastic medium into which
other ingredients are embedded. A dough is typically prepared by mixing,
and kneading or "working" and is often stiff enough to cut into various
shapes.

[0087]In contrast, "batter" as used herein refers to an intermediate food
product that comprises flour, water, eggs and salt and optionally fat and
sugars that are a starch batter-based composition. In a batter, gluten
development is purposefully minimized. Batters are inelastic. Liquid
added to make the batter forms a continuous batter medium in which other
ingredients are dispersed. A batter cooks into a soft, moist and
sometimes crumbly product. A batter is typically prepared by blending,
creaming, stirring or whipping and is generally thin enough to pour or
scoop or squeeze out of container. Thicker batters in the form of a paste
have certain properties of thickness similar to doughs but nonetheless
are quite different therefrom.

[0088]"Dough" as used herein further refers to an intermediate food
product that has a low water concentration. Prior to piece forming and
case hardening, the dough, has a water activity within a range of about
0.95 to 0.99 and a moisture content ranging from about 30-40%

[0089]In the present invention, in the preferred embodiment, at least a
major portion (greater than about 51%) of the flour used to prepare the
dough is a wheat flour. The flour ingredients can further include a minor
portion (less than about 49%) of additional flour types. For example, in
certain variations, the minor portion can includes corn flour, corn masa,
masa harina and mixtures thereof. Good results are obtained when a medium
protein of "all-purpose" wheat flour (having a gluten based protein
content ranging from about 9-12% is used to supply wheat flour. Bread
flour (having a higher gluten protein content ranging from about 12% to
16%) can also be used. Lower protein content cake flours (having a
protein content of less than 6%) are less preferred although blends of
cake or pastry flours and bread flour (to achieve an averaged wheat flour
protein content ranging from about 6-9%) can be used. In a preferred
embodiment, a flour is employed having about 11.5% protein.

[0090]The doughs can also comprise added ingredients to increase dough
stability, to improve eating quality, and to prolong palatability.

[0091]Unlike traditional fresh tortilla dough formulations, the present
dough formulation of the present invention, in highly preferred
embodiments, comprise from about 1% to about 15% of an edible fat or
shortening ingredient, preferably about 4-10% and for best results about
9%. A shortening component adds richness to the eating properties of the
finished baked goods as well as aids in the leavening process. Most
importantly, the shortening component provides additional flexibility or
pliability to the tortilla product over its extended shelf life.

[0092]Preferred for use herein are shortening ingredients that are solid
at room temperature to provide physical stability. Useful herein to
provide such room temperature solid fats are hydrogenated fats such as
obtained from common vegetable oils such as soy, corn, canola, safflower,
cottonseed, and the like. However, since hydrogenated fats can be sources
of undesirable trans fatty acids, current health trends disfavour usage
of hydrogenated fats. Thus, preferred for use herein are those naturally
occurring fats that are solid at room temperature without hydrogenation.
Among these, preferred for use herein are palm, coconut, palm kernel oil,
and fractions and mixtures thereof. Of course, mixtures of naturally
solid fats and fats obtained by hydrogenation are contemplated.

[0093]The present invention can further comprise about 2% to about 15% of
a humectant on a dry weight basis, preferably about 4% to about 8%.
Humectant addition is helpful in achieving the present water activity
levels and the microbial shelf stability at room temperature provided by
the present food products. The humectant can be any commonly employed
humectants ingredient. Preferred humectants for use herein are selected
from the group consisting of glycerin, glycerol, mannitol, propylene
glycol, sorbitol, xylitol and mixtures thereof. Preferred for use herein
is glycerin by itself or a mixture of sorbitol and glycerin.

[0094]The dough can additionally include about 0.1% to about 4% salt,
preferably about 0.5% to 3% salt.

[0095]Unlike traditional fresh tortilla dough formulations, the dough of
the invention can and in preferred embodiments do, also comprise a
chemical leavening system or baking powder to provide a chemically
leavened wheat dough. The chemical leavening or baking powder useful
herein are such as those containing sodium bicarbonate and the
combination of one or more baking acids with sodium bicarbonate. Baking
acids useful for chemical leavening and dough mixtures include
monocalcium phosphate, glucano-deltalactone, potassium hydrogen tartrate,
dimagnesium phosphate, and mixtures thereof. One or more baking acids can
be combined with the sodium bicarbonate to form the chemical leavening
agent.

[0097]One preferred leavening system which provides this combination of
fast and slow acting leaveners is baking powder that combines baking soda
or sodium bicarbonate with any of sodium aluminum sulfate, sodium
aluminum pyrophosphate, monocalcium phosphate and mixtures thereof. In
another preferred embodiment, medium acting leaveners such as SAPP 28
(sodium acid pyrophosphate) can be used. (SAPPs can react in a range of
rates with SAPP 28 being about in the middle). It is believed that the
fast acting leavening agent provides improved texture or rheology when
the dough is heat set, and the slow acting leavening agent provides
desired textural attributes when the dough is finish cooked such as by
baking.

[0098]The formulations for the dough from which the present shaped
tortilla pieces are fabricated additionally can include one or more
emulsifiers. Specifically, the present formulations can further comprise
about 0.2% to about 1.5% of a emulsifier on a dry weight basis,
preferably about 0.4% to about 0.8%. Emulsifiers, which strengthen the
dough, give improved mixing and handling tolerance, increase loaf volume,
improve mechanical slicing characteristics, and can retard staling.
Emulsifiers typically are surface active agents that stabilize mixtures
of hydro-phobic and hydrophilic substances by lowering the interfacial
tension between usually immiscible substances. Emulsifying agents which
can be used include mono- and diglycerides of fatty acids, propylene
glycol mono-diesters of fatty acids, glycerol-lactose esters of fatty
acids, ethoxylated or succinylated mono- and diglycerides, lecithin,
diacetyl tartaric acid esters or mono-diglycerides, sucrose esters of
glycerol, or equivalents thereof and mixtures thereof. Preferred
emulsifiers include mixtures of diacetyl tartaric acid esters, and
succinylated mono- and diglycerides. Emulsifying agents can be used
singly or in combination with typical usage levels of less than 3% by
weight.

[0099]The formulations for the dough from which the present shaped
tortilla pieces are fabricated additionally can include one or more dough
conditioners. The present formulations can her comprise about 0.2% to
about 1.5% of a dough conditioners on a dry weight basis, preferably
about 0.4% to about 0.8%. The dough conditioners used herein can be of
the oxidizing type, reducing type or both. Oxidizing agents or oxidizing
type dough conditioners strengthen the dough. Thus employment of
oxidizing dough conditions can lead to economies with shortened makeup
times or by compensating for low protein in the flour. More commonly used
oxidizers today include azodicarbonamide (ADA), which can be used at up
to 45 ppm in the United States, and L-ascorbic acid (LAA), or vitamin C,
for which there is no usage limit in the United States. ADA works very
quickly, and can easily be overused, producing dry dough that is hard to
work, low volume and cracked bread surfaces. LAA works slowly; moderate
overuse has no deleterious effect on quality and it is commonly used at
about 75 ppm. LAA is currently the only oxidizing agent permitted in the
European baking industry.

[0100]Useful dough conditioners can also include reducing agents, which
serve to encourage the development of gluten, thus shortening the mixing
time and decreasing the amount of mixing energy that is needed. The most
commonly used reducing agent, L-cysteine. Also useful is sodium
metabisulfite.

[0101]The chemically leavened dough of the present invention optionally
includes a variety of ingredients suitable for rendering finished baked
goods prepared therefrom more organoleptically desirable. These optional
components include an anti-mycotic agent, anti-oxidants or preservatives,
and flavor/coloring agents.

[0102]Especially preferred for use herein are flavour and color additives
intended to mimic the yellow color of traditional yellow corn. While in
certain jurisdictions, certain synthetic yellow colorants are permitted,
especially useful herein for such color additives are those natural
yellow colorants such as turmeric, beta carotene, and/or annatto and
mixtures thereof. Also, while any edible vegetable oil can be used,
preferred for flavor and color is corn oil.

[0103]Useful anti-mycotic agents include sorbic acid and its derivatives
such as sodium or potassium sorbate, propionic acid and its derivatives,
sodium diacetate, monocalcium phosphate, lactic acid, citric acid
parabens and so on. These agents are present in an amount to aid in the
inhibition of growth of undesirable yeast and/or molds, typically about
0.01 to 1.0% of dry weight basis ingredient such as sodium propionate,
potassium sorbate, calcium propionate, sorbic acid and mixtures thereof.
The anti-mycotic ingredient can be present in a range of about 0.01% to
about 1.0% on a dry weight basis of the dry mix composition Where legally
permitted, the products herein can additionally include common levels and
types of anti-oxidants and preservatives such as vitamin E, BHA
(butylated hydroxyanisole), BET (butylated hydroxytoluene), TBHQ
(tert-butyl hydroquinone), and mixtures thereof, up to levels permitted
by current food laws.

[0104]The tortilla dough is preferably not acidified and thus ranges in pH
from about 6.0 to 8.0.

[0105]The present invention provides methods for preparing a finished
package soft shaped tortilla food article. The present methods can
include steps of providing a quantities of a chemically leavened gluten
plastic dough; forming into shaped heat set pieces; baking; and packaging
a number of pieces within a modified atmosphere package.

[0106]The chemically leavened doughs of the present invention are prepared
by blending the essential and optional components such as wheat flour,
optionally corn flour or corn masa, salt, sugar, shortening or oil,
water; glycerol or other polyol; and leavening system together in such a
conventional manner as to produce a well blended developed gluten dough.
Conveniently, the chemically leavened dough can be prepared from a first
liquid premix blend and a second dry premix blend. The liquid premix
blend can include the oil or liquid shortening, eggs, glycerol,
emulsifiers and so on. The dry blend can include flour(s), sugar(s),
salt; leavening and so on. The dry blend and liquid blend are then
combined to form a gluten based plastic or viscoelastic dough. The
chemically leavened dough is, for example, prepared in a batch or a
continuous mixing device. The moisture content of the dough can range
from about 20% to about 40% resulting in an Aw ranging from about
0.95 to about 0.99.

[0107]In a preferred variation, the dough is a highly developed dough as
expressed in Brabender units. Characterization of the doughs in Brabender
unit ("BU's") is well known in the dough art and these units measure the
doughs resistance to turning on a mixer hook. More highly developed or
worked doughs exhibit greater resistance to turning. Good results are
obtained herein when the present doughs have a Brabender value ranging
from about 500 to 1000 BU. In more preferred variations, the dough is
developed to its peak or, otherwise expressed, to maximum gluten strength
development.

[0108]The dough is provided in small measured quantities useful herein for
making the present sized and shaped pieces. In a preferred embodiment in
the preparation of smaller base pieces, these quantities range from about
5-25 g each. For larger soft shaped tortilla base pieces, a larger
quantity (e.g., 40-60 g) can be used. Any technique or apparatus can be
used to provide such measured quantities of dough. For example, the dough
can be formed into a continuous shape such as a rope, sheet or ribbon and
the continuous strand sectioned (such as by a reciprocating guillotine
knife) into desired uniform (±10%) quantities, e.g., if a 10 g
quantity is desired, then each quantity will be 10 g±1 g. In small
scale commercial production, simple manual cutting the dough into such
small quantities is the preferred technique.

[0109]In preferred embodiments, the preparation methods additionally
comprise a step dough of resting the measured quantity of dough to
provide a measured quantity of rested dough. Good results are obtained
when the measured quantities of dough, e.g., dough balls, are allowed to
rest for 5-10 minutes at ambient temperatures. A resting step is useful
for better facility of the dough conforming to the shape of the dough
without thickness variations or weak spots in the finished pieces.

[0110]The present methods can further include the step of forming the
individual quantities of chemically leavened dough, preferably rested,
into shaped, leavened heat set soft shaped tortilla pieces. In one
variation, this step is practiced as a single step cooking and forming
operation employing a suitably shaped and configured heated shape press
molds. The tortilla press mold is heated to provide a mold surface
temperature ranging from about 190° C. to 205° C.
(375° F. to about 400° F.). A quantity (e.g., 40-60 g) of
the rested dough is placed within the shape press mold and closed and
heated to initiate leavening and to heat set the soft shaped tortilla
base piece. Good results are obtained when the heating step is practiced
for about 45-60 seconds, preferably about 45-55 seconds. The heating
operation heats the dough to temperatures sufficient to gelatinize and
hydrate the starch components substantially completely and to denature
the protein of its gluten content (85-95° C.; 185-200° F.).
The formed heating step results in some moisture loss that adds to the
leavening effect and results in hot cooked shaped pieces having a
moisture content ranging from about 28% or less. The now cooked and set
shaped soft tortilla piece is then allowed to coot in the mold through
its glass transition temperature ("Tg") to room temperature to
provide a tortilla piece in a sized and shaped set form piece that is no
longer entirely plastic but semi-rigid, i.e., sufficiently rigid
(although still pliable) to hold or maintain its shape.

[0111]However, in more preferred variations, the cooking step is practiced
in sub-steps wherein only a par-bake operation is practiced at shorter
times, e.g., in the heated press mold and the cooking step is completed
in a subsequent finish baking sub-step. By reducing the time required in
the press mold, greater through-puts can be obtained for greater cost
efficiency. In this preferred variation, the initial heating or forming
sub-step results in a par-baked or intermediated food item that is no
longer a plastic dough.

[0112]During the forming sub-step, the fast and medium acting acids of the
leavening system initiates the leavening process such that about 90% or
more of the leavening occurs during this step. While the center plain
portion is confined to a thickness of 1-2 mm by the tortilla press to
provide a density in the center plain portion ranging from about 0.7-0.9
g/cc, Further expansion in the oven during the baking step allows the
piece to chemical leavening to expand to a density of about 0.3-0.5 g/cc
and a thickness of about 1-5 mm.

[0113]The present method can further include a step finish cooking the set
par cooked base piece to form a finished soft shaped tortilla base piece
food product. In preferred form, the finish cooking is a baking step that
reduces the moisture content of the par cooked set piece from an initial
value of about 26%-30% moisture to a finish moisture content ranging from
about 25% or less and an Aw of 0.88 or less. (There is actually only
a small reduction in moisture in the press, the moisture went from 37 to
33% moisture. Most of the moisture loss is in the oven.) Conveniently,
the par cooked base piece items are baked at about 175° C. to
210° C. for about 1-5 minutes, preferably about 2-4 minutes.
Preferred for use herein is a belt oven using a combination of radiant,
and conduction heating to provide a finished product having not only the
desired finished moisture content but also the desirable toast points
described above. In commercial form, a moving belt conveys the par cooked
pieces into an elongated oven of sufficient length and at a line speed
sufficient to provide a residence time within the oven to provide the
desired baking or finish cook times herein. In other variations, a
combination of one or more baking and heating steps can be practiced to
provide not only the finish cooking of any raw portions of the piece but
also to provide any desired toast points feature herein. The preferred
method for us is to use a tortilla baking oven that is a series of plates
or belts where the soft shaped tortilla are heated by conduction and
radiant heat. An impingement oven using high velocity hot air would also
work but the belt oven is preferred.

[0114]The finished base pieces so prepared are generally entirely cooked
and any raw dough such as in the peripheral ring portion is finish cooked
to at least 90% starch gelatinized.

[0115]After cooling to about room temperature, a number of finished soft
shaped tortilla base pieces are packaged in a suitable food package. In
one embodiment, the number of soft shaped tortilla pieces are formed or
aggregated into one or more stacks or other ordered arrangement or
arranged array such as the two side-by-side short stacks (not shown). In
certain variations, preparation of the arranged array or protection of
the arranged array is facilitated by a tray, support board or other
secondary package element such as the U-board described above. In these
variations, the packaging step can include a sub-step of mounting a
number of finished soft shaped tortilla base pieces such as in a
confronting relationship on a support member or carrier prior to
disposing the numbers of finished pieces within the food package.

[0116]In another less preferred embodiment, the number of finished base
pieces are in the form of a loose random mixture in the food package.
While easier to add to a food package in a random form, such arrangements
are less visually appealing. Also, such arrangements can provide less
protection to the finished soft shaped tortilla base pieces against
breakage during handling.

[0117]Suitable for use herein is a food package capable of hermetic
sealing against moisture and optionally oxygen transport over extended
shelf lies ranging from about 6-18 months are room temperature storage.
In preferred form, the food package is fabricated at least in part from a
flexible packaging film to form a bag or pouch. In certain variations,
one or more stacks each individually wrapped in a sealed flexible
packaging film with a modified packaging atmosphere are bundled together
and provided with an overwrap also conveniently fabricated from a
flexible packaging film.

[0118]The packaging step can also, and in the preferred embodiment, does
include providing the food package with a modified packaging atmosphere.
More particularly, the sub-step can include flushing the food package
immediately prior to finish sealing with a low oxygen level (below 4%
O2, preferably below 1% O2) packaging gas such as CO2,
N2, N2O and/or other inert gas. The food package is then sealed
to provide finished packaged food articles of the present invention.
Preferably, the finished food packaged is hermetically sealed such as to
provide a low oxygen packaging headspace environment of less than 4%
O2, preferably 1%, and for best results less than 0.5% during an
entire six month of room temperature storage.

[0119]For some embodiments, the headspace comprises at least 10% (v/v) of
CO2, and can be at least 20%. In a preferred embodiment, the
headspace comprises a blend of 40% CO2 and 60% N2. At such
levels, the CO2 provides modest preservative properties against
spoilage.

[0120]In the preferred embodiment, the food package can be provided or
made from a moisture loss resistant low oxygen permeability flexible
packaging film to provide a hermetically sealed food package. In
preferred form, the packaging material has an oxygen permeability value
of less than 2.5 cc/cm2/day. In other embodiments, the packaging can
be in the form of a tin, plastic tub or cup or a paperboard canister
provided that the container can maintain a low oxygen packaging
atmosphere for the extended shelf lives contemplated herein. Thereafter,
the present inventions in its method of preparation aspect can further
include a step of inserting the finished packaged food articles into a
carton. The shelf stable multi-texture wheat based soft shaped tortilla
base pieces can be combined with wet or dry sauce pouches to provide meal
kits for the at home preparation of Mexican soft shaped tortilla finished
food products of superior taste and texture.

[0121]In a preferred variation, the packaging film is clear or has at
least portion that are transparent so that the product can be view within
the food package. In another variation, at least a portion of the
packaging film is provided by a low oxygen permeability flexible laminate
packaging film having a foil layer.

[0122]While the package can be overpressurized, preferred herein is an
unpressurizable container for containing and storing the soft shaped
tortilla since overpressurized containers are more expensive and
unnecessary herein.

[0123]Also, pouches of wet and/or dry secondary food components can be
prepared and inserted into the carton to form dinner kits. The kits can
also include cans or tins of other ingredients, e.g., diced olives,
pimentos, or peppers, or refried beans. The filled cartons are then
finished seated to provide the finished kit items of the present
invention. The kit can include preparation instructions such as by a
preparation instruction legend printed onto the carton exterior.

[0125]More specifically, FIG. 10 depicts a meal or dinner kit of the
present invention. FIG. 10 depicts that the meal kit can include a carton
or other container. The kit includes at least one packaged soft shaped
tortilla base pieces article or the like as described above disposed
within a container. The container can be a conventional paperboard carton
optionally having an easy open feature such as tear strip. The kit also
includes at least one seated container of secondary ingredients. The
container of secondary ingredients can be, for example, either a wet
and/or a dry pouch. The kit can further include one or more preparation
instruction legends. Legend(s) can include reheating suggestions, recipes
for making toppings, or instructions on how to prepare a seasoned meat
toping ingredient. Such legends can be on the carton as depicted and/or
on the individual pouches (not shown). The kit container does not need to
have a modified atmosphere. In certain variations, the kit can
additionally include a clear film overwrap (not shown) to provide extra
packaging protection. In still other variations, the kit can include a
sealed container such as can or cup for including additional ingredients,
e.g., refried beans in addition or in substitution for the wet or dry
pouches. In still other variations, the kit can include a tray or other
supplemental packaging support element (not shown) to prevent component
movement within the carton.

[0126]For example, the pouch can contain a wet sauce such as a salsa sauce
or cheese sauce. Wet sauce pouches are typically aseptically packaged for
extended shelf lives. In another variation, the pouch can include a dry
mix of seasoning ingredients to add to meat to form a flavored meat
topping such as a taco seasoning blend. In this variation, dry blends of
solid seasonings, salt, colors, seasoning, can be blended with
pre-gelatinized starch. The dry seasonings can be mixed by the consumer
with water, heated to form a flavored thickened liquid or thin paste and
blended with consumer supplied cooked meat to form the flavored or
seasoned meat topping ingredient or component. While a variety of
seasoning mixes can be prepared, since cumin is a component of many
Mexican dishes, the dry mix preferably includes at least cumin and salt.
In still other variations, the pouch can include a cream ingredient such
as a ready-to-spread topping frosting for those executions wherein the
soft shaped tortilla is used as a dessert foundation. In certain
variations, the kit can contain one or more pouches of dry and/or wet
secondary kit ingredients such as pouches.

[0127]In still another embodiment, a previously formed tortilla (e.g., a
conventional store-bought tortilla) is used to form a bowl after shaping
and further heating to form a shaped product that is then heated until it
retains its shape after cooling.

[0128]Preferably, the shaped tortillas are prepared so as to minimize the
formation of discontinuities (e.g., bubbles and voids) during commercial
production. Discontinuities in tortillas can be minimized by providing
flour of the proper granulation, using the proper ratios of ingredients,
maintaining the proper moisture level in the dough, heating and baking
properly, and avoiding the use of moulds having unnecessarily complex
geometries.

[0129]In one particular aspect, the shaped tortilla is reheated prior to
being filled with heated filling. In another aspect, a heatable filling
is placed in the shaped tortilla and then heated together. In yet another
aspect, an individual or machine fills one or more shaped tortillas with
heatable filling and then leaves the one or more tortillas for another
individual to or machine to fill with other types of filling. Finally, in
still another aspect, an individual or machine leaves one or more shaped
tortillas for another individual or machine to fill with filling.

EXAMPLES

[0130]The examples described herein are for purposes of illustrating
embodiments of the invention. Other embodiments, methods, and types of
analyses are within the scope of persons of ordinary skill in the
molecular diagnostic arts and need not be described in detail hereon.
Other embodiments within the scope of the art are considered to be part
of this invention.

[0133]1.) Ingredients were combined in mixer2.) These were mixed 4-10
minutes on medium speed3.) The dough was allowed to rest five minutes4.)
The dough was divided into 40-60 gram balls5.) The dough balls were
pressed in press comprising a preheated male and female mould with
desired shape @400° F. (˜205° C.) for 1-3 seconds6.)
The shapes were removed from the moulds and baked in a tortilla oven
@400° F. (˜205° C.) for 30-90 seconds7.) The shapes
were cooled five minutes on cooling rack8.) The soft shaped tortillas
were packaged9.) Final tortilla moisture content was measured at 23-28%,
Water Activity at <0.880

Example 4

Soft Shaped Tortilla Procedure 2

[0134]1.) Ingredients were combined in mixer2.) These were mixed 4-10
minutes on medium speed3.) The dough was allowed to rest five minutes4.)
The dough was divided into 60 gram balls5.) The dough balls were pressed
in press comprising preheated male and female moulds with desired shape
@400° F. (˜205° C.) for 15-90 seconds6.) The shapes
were removed from the moulds and cooled 5 minutes on cooling rack7.) The
soft shaped tortillas were packaged8.) Final tortilla moisture content
was measured at 23-28%, Water Activity at <0.880

Example 5

Soft Shaped Tortilla Procedure 3

[0135]1.) Ingredients were combined in mixer2.) These were mixed 4-10
minutes on medium speed3.) The dough was allowed to rest five minutes4.)
The dough was divided into 40 gram balls5.) The dough balls were pressed
in tortilla press @400° F. (˜205° C.) for 1-3
seconds6.) These were baked in tortilla oven @400° F.
(˜205° C.) for 30-90 seconds7.) The baked tortillas were
pressed into male and female moulds of desired shapes8.) These were
cooled, while still in the moulds, five minutes on cooling rack9.) The
soft shaped tortillas were packaged10.) Final tortilla moisture content
was measured at 23-28%, Water Activity at <0.88

Example 6

Soft Shaped Tortilla Procedure 4

[0136]1.) Ingredients were combined in mixer2.) These were mixed 4-10
minutes on medium speed3.) The dough was allowed to rest five minutes4.)
The dough was sheeted to a thickness of 1-3 mm5.) The sheeted dough was
folded around male mould6.) The sheeted dough was cut around male
mould7.) The sheeted dough was pressed into female mould8.) The dough was
in heated in the preheated moulds at 400° F. (˜205°
C.) for 1-3 seconds9.) The shapes were removed from the moulds and baked
in tortilla oven @400° F. (˜205° C.) for 30-90
seconds10.) The shapes were cooled five minutes on cooling rack11.) The
soft shaped tortillas were packaged12.) Final tortilla moisture content
was measured at 23-28%, Water Activity at <0.88

Example 7

Soft Shaped Tortilla Procedure 5

[0137]1.) Ingredients are combined in mixer2.) These are mixed 1-10
minutes on medium speed3.) Dough or batter is injected into preheated
mould at 400° F. (205° C.) for 1-3 seconds.4.) The shapes
are removed from mould.5.) The shapes are baked in tortilla oven
@400° F. (˜205° C.) for 30-90 seconds6.) The shapes
are cooled 5 minutes on cooling rack7.) The soft shaped tortillas are
packaged8.) Final tortilla moisture content is measured at 23-28%, Water
Activity at <0.88

Example 8

Soft Shaped Tortilla Procedure 6

[0138]1.) Ingredients are combined in mixer2.) These are mixed 1-10
minutes on medium speed3.) Dough or batter is injected into preheated
mould at 400° F. (˜205° C.) for 3-20 seconds.4.) The
shapes are removed from mould5.) The shapes are cooled 5 minutes on
cooling rack6.) The soft shaped tortillas are packaged7.) Final tortilla
moisture content is measured at 23-28%, Water Activity at <0.88

[0139]The invention has been described herein, with reference to certain
preferred embodiments, in order to assist the reader in practicing the
invention without undue experimentation. However, a person having
ordinary skill in the art will readily recognize that many of the
components and parameters can be varied or modified to a certain extent
without departing from the essence of the invention. Furthermore, titles,
headings, or the like are provided to enhance the reader's comprehension
of this document, and should not be read as limiting the scope of the
present invention.

[0140]The entire disclosures of any patent applications, patents, and
publications, cited above and below, if any, are hereby incorporated by
reference in their entirety. Any discussion of such disclosures
throughout the specification should in no way be considered as an
admission that such disclosure is widely known or forms part of common
general knowledge in the field.

[0141]Throughout this specification, and any sections which follow, unless
the context requires otherwise, the words "comprise," "comprising" and
the like, are to be construed in an inclusive sense as opposed to an
exclusive sense, that is to say, in the sense of "including, but not
limited to".